Layered thin film heater and method of fabrication

ABSTRACT

A method of forming thin film heater traces on a wafer chuck includes positioning a pattern, that forms openings corresponding to a desired layout of the heater traces, in proximity to the wafer chuck. The method includes sputtering a material toward the pattern and the wafer chuck such that a portion of the material passes through the openings and adheres to the wafer chuck to form the heater traces. A method of forming thin film heater traces on a wafer chuck includes sputtering a blanket layer of a material onto the wafer chuck, and patterning a photoresist layer utilizing photolithography. The photoresist layer covers the blanket layer in an intended layout of the heater traces, exposing the blanket layer in areas that are not part of the intended layout. The method removes the areas that are not part of the intended layout by etching, and removes the photoresist layer.

TECHNICAL FIELD

The present disclosure is directed to technology for fabricating heater elements, as may be used, for example, in semiconductor wafer processing. In particular, systems and methods of fabricating thin film heater traces for wafer chucks are disclosed.

BACKGROUND

Semiconductor wafer processing is sometimes performed in batches, with all wafers in a cassette being subjected to a process simultaneously. However, single water processing is becoming more prevalent because point to point process variations in a single water processing apparatus can usually be controlled more precisely. In single wafer processing, wafers are usually moved by automated handlers from cassettes to a water chuck and back again. In some cases, the wafer sits on the chuck, held in place only by gravity. In other cases, the wafer is held either by applying a vacuum to one or more backside areas of the water through holes in the chuck (e.g., a “vacuum chuck”) or by applying a voltage to a chuck that is formed of an insulator overlying a conductor (e.g., an “electrostatic chuck” (ESC)). Processing may involve controlling the temperature of the chuck and thus the wafer. Certain chucks have both heating and cooling capability, while others have only heating capability. Chucks can be heated by running a heated fluid through the chuck or by passing current through a resistive heater element integrated with the chuck.

Heating capability for a wafer chuck is often implemented by forming resistive heater traces on the chuck. Presently, such heater traces are often fabricated using thick film technologies such as screen printing, ink jet printing or other liquid dispensing techniques. In these techniques, forming precise lines and corners, as well as forming layers with precise thickness control, can be challenging.

SUMMARY

The present disclosure is directed to formation of heater traces, formed by sputtering, on wafer chucks for processing equipment. Such heater traces are expected to provide improved resistance control and thus improved process control achieved by the processing equipment, compared to prior art heater traces.

In an embodiment, a method of forming thin film heater traces on a wafer chuck includes positioning a pattern in proximity to the wafer chuck, the pattern forming openings corresponding to a desired layout of the heater traces. The method also includes sputtering a material toward the pattern and the wafer chuck such that a portion of the material passes through the openings and adheres to the wafer chuck to form the heater traces.

In an embodiment, a method of forming thin film heater traces on a wafer chuck includes sputtering a material onto the wafer chuck to form a blanket layer of the material, and patterning a photoresist layer utilizing photolithography. The photoresist layer covers the blanket layer in an intended pattern of the heater traces, while exposing the blanket layer in areas that are not part of the intended pattern. The method also includes removing the areas that are not part of the intended pattern by etching, and removing the photoresist layer.

In an embodiment, a heated wafer chuck for semiconductor processing includes a wafer chuck having a dielectric surface, and one or more sputtered thin film heater traces. The one or more sputtered heater traces include copper, molybdenum or alloys thereof. A layout of the heater traces includes landing pads for electrical connections. A dielectric layer overlies the one or more sputtered thin film heater traces. The dielectric layer forms vias over the landing pads, for the electrical connections to make contact to the landing pads.

Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the invention. The features and advantages of the invention may be realized and attained by means of the instrumentalities, combinations, and methods described in the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates major elements of a single wafer semiconductor processing system, according to an embodiment.

FIG. 2 schematically illustrates a single wafer chuck, according to an embodiment.

FIGS. 3A and 3B are schematic cross-sectional illustrations of two variations of the single wafer chuck of FIG. 2, according to embodiments.

FIGS. 4, 5 and 6 are cross-sectional, schematic illustrations of methods of forming thin film heater traces with sputtering, according to embodiments.

FIG. 7 shows thin film heater traces on a chuck, representing the result of any of the methods illustrated in FIGS. 4, 5 and 6.

DETAILED DESCRIPTION

The present disclosure may be understood by reference to the following detailed description taken in conjunction with the drawings briefly described below, wherein like reference numerals are used throughout the several drawings to refer to similar components. It is noted that, for purposes of illustrative clarity, certain elements in the drawings may not be drawn to scale. Specific instances of an item may be referred to by use of a numeral in parentheses (e.g., landing pads 220(1), 220(2)) while numerals without parentheses refer to any such item (e.g., landing pads 220). In instances where multiple instances of an item are shown, only some of the instances may be labeled, for clarity of illustration.

FIG. 1 schematically illustrates major elements of a single wafer, semiconductor wafer processing system 100, according to an embodiment. Processing system 100 includes a housing 110 for a wafer interface 115, a user interface 120, a process chamber 130, a controller 140 and one or more power supplies 150. Process chamber 130 includes one or more wafer chucks 135, upon which wafer interface 115 can place a wafer 50 for processing. The elements shown as part of system 100 are listed by way of example and are not exhaustive. Many other possible elements, such as: pressure and/or flow controllers; electrodes, magnetic cores and/or other electromagnetic apparatus; mechanical, pressure, temperature, chemical, optical and/or electronic sensors; viewing and/or other access ports; and the like may also be included, but are not shown for clarity of illustration. Internal connections and cooperation of the elements shown within system 100 are also not shown for clarity of illustration. Representative utilities such as gases 155, vacuum pumps 160, radio frequency generators (RE Gen) 165 and/or electrical power 170 may connect with system 100. Like the elements shown in system 100, the utilities shown as connected with system 100 are intended as illustrative rather than exhaustive; other types of utilities such as heating or cooling fluids, pressurized air, data exchange (e.g., networking or automation) capabilities, waste disposal systems and the like may also be connected with system 100, but are not shown for clarity of illustration.

FIG. 2 schematically illustrates a single wafer chuck 200, according to an embodiment. Chuck 200 is suitable for use as chuck 135 shown in FIG. 1. Chuck 200 may be configured as an electrostatic chuck or a vacuum chuck to hold wafer 50 for processing, according to structure described below in connection with FIGS. 3A and 3B. Chuck 200 includes a thin film heater trace 210 that is formed by sputtering. The shape of thin film heater trace 210 shown in FIG. 2 is for illustrative purposes only and may vary, in embodiments, in order to provide adequate and/or uniform heating of wafer 50. In particular, embodiments herein may include multiple thin film heater traces 210 that heat differing radial and/or lateral zones of chuck 200. Multiple thin film heater traces may be used to compensate for any nonuniformity in temperature that may arise, due to minor asymmetry and/or external reasons such as transfers of heat among chuck 200 and wafers in process, plasmas, process chemicals and/or other parts of equipment in which chuck 200 resides. Thin film heater trace 210 terminates in landing pads 220(1) and 220(2) that may connect by electrical connections to a power supply (e.g., one of power supplies 150 shown in FIG. 1) that provides current for heating chuck 200.

Chuck 200 may be formed of an insulator, for example ceramic, with heater trace 210 formed directly thereon. Exemplary insulators of which chuck 200 may be formed include alumina (Al₂O₃) and aluminum nitride (AlN). Alternatively, chuck 200 may be formed of a conductor overlaid with a dielectric layer with heater trace 210 formed on an opposite side of the dielectric layer from the conductor. Exemplary conductors of which chuck 200 may be formed include brass, stainless steel and aluminum; exemplary dielectric layers include silicon dioxide (SiO₂), silicon nitride (Si₃N₄) and mixtures thereof (Si_(x)O_(y)N_(z)). Thin film heater trace 210 may be formed of copper, molybdenum, alloys thereof, and/or other materials that are typically utilized for heater traces.

Chuck 200 may optionally include one or more sensors 230 (for example, thermocouples) to provide temperature measurements of chuck 200. Sensors 230 may, in embodiments, be embedded within channels formed in chuck 200. Although only one sensor 230 is shown in FIG. 2, it is understood that multiple sensors 230 may be disposed at various locations to provide temperature measurements at each of the locations. In operation, a power supply (e.g., one of power supplies 150 shown in FIG. 1) supplies power through electrical connections to thin film heater trace 210, heating chuck 200 to an appropriate temperature for wafer processing. Temperature measured by sensors 230 and/or electrical power delivered to heater trace 210 may be measured and reported continuously or intermittently to an operator of equipment that includes chuck 200. A broken line 3-3′ shows a plane corresponding to the schematic views shown in FIGS. 3A, 3B.

The choice of sputtering as a method for forming the material of heater trace 210 enables significant improvements. Existing heater traces for wafer chucks are often formed by thick film fabrication methods (e.g., screen printing) to minimize cost. Such existing heater traces can have compositional, thickness and/or lateral dimensional variations, and instabilities over time and use that can adversely affect the repeatability and point to point uniformity of the heater traces. In an example of such effects, wafer processing uniformity requirements place tight specification tolerances on resistance of heater traces and power delivery required to achieve a given wafer chuck temperature. Native variation of as-fabricated resistance measurements of thin film heaters made with thin film fabrication results in some wafer chucks whose heater traces exceed the resistance tolerances and must be scrapped before installation, while the wafer chucks that are within tolerances tend to fill the specification “window.” Furthermore, over time, even the wafer chucks that are within tolerances generate a wide distribution of power delivery required to achieve a given wafer chuck temperature.

Sputtering can be expensive in terms of capital equipment cost and per unit processed, but may provide more precise thickness and compositional control than thick film techniques, resulting in both cost savings and improved process control of the finished product. Sputtering is also compatible with patterning techniques that can minimize lateral dimensional variations, as discussed below. It is expected that thin film heater traces manufactured by sputtering according to the techniques below will provide tighter distributions of resistance and power delivery required to achieve a given wafer chuck temperature. For example, it is expected that all wafer chucks manufactured will be within resistance specifications, thus reducing cost by reducing or eliminating out-of-tolerance wafer chucks, and reducing resistance variation in the overall distribution of wafer chucks. The reduced resistance variation is expected to, in turn, reduce power delivery variation required to achieve a given wafer chuck temperature, thus improving process uniformity of the equipment utilizing such wafer chucks.

FIGS. 3A and 3B are schematic cross-sectional illustrations of two versions of chuck 200, denoted as 200(1) and 200(2) respectively. In FIG. 3A, chuck 200(1) is an electrostatic chuck that includes a conductive base 240. Chuck 200(1) is formed by forming a first insulator 250 upon base 240, sputtering thin film heater trace 210, and finally forming a second insulator 260 over both first insulator 250 and thin film heater trace 210. First and second insulators 250 and 260 typically provide mechanical integrity, chemical passivation and/or scratch protection for an upper surface of chuck 200(1) and for heater trace 210. The vertical dimension of thin film heater trace 210 is exaggerated for illustrative clarity. Vias are provided in second insulator 260 (outside of the cross-sectional plane shown in FIG. 3A) to facilitate electrical contact to heater trace 210, and are typically formed by a masking and etching process.

In FIG. 3B, chuck 200(2) is a vacuum chuck that includes a base 270 formed of an insulator, and containing vacuum passages 290 that optionally connect with a vacuum connector 295 for further connection to a vacuum source. Chuck 200(2) is formed by forming vacuum passages 290 in base 270, sputtering thin film heater trace 210, forming an insulator 280 over heater trace 210, and completing vacuum passages 290 through insulator 280 such that vacuum can be applied to a backside of wafer 50 to hold wafer 50 in place. Vacuum passages 290 may intersect a surface of chuck 200(2) as shown, or may intersect rings or other surface structure of chuck 200(2) to engage a greater backside area of wafer 50, to hold wafer 50 securely to chuck 200(2). Insulator 280 typically provides mechanical integrity, chemical passivation and/or scratch protection for an upper surface of chuck 200(2) and for thin film heater trace 210. Again, the vertical dimension of thin film heater trace 210 is exaggerated for illustrative clarity, and vias are provided in second insulator 260 (outside of the cross-sectional plane shown in FIG. 3B) to facilitate electrical contact to heater trace 210.

FIGS. 4, 5 and 6 are cross-sectional, schematic illustrations of methods of forming thin film heater traces with sputtering, according to embodiments. FIG. 7 shows thin film heater traces 390 on a chuck 300, representing the result of any of the methods illustrated in FIG. 4, 5 or 6. It is understood that the shown geometries of heater traces 390 are for purposes of illustration only and may vary in embodiments. Also, chuck 300 is represented only as a single block but may have structure such as insulator layers, vacuum channels, channels for sensors and the like that do not interfere with the processes illustrated. Furthermore, upon reaching the condition illustrated in FIG. 7, further processes may be implemented (e.g., deposition of further dielectrics, etc.)

1. Exemplary Stencil Mask Technique

FIG. 4 shows beginnings of thin film heater traces 390 being formed by sputtering metal atoms 340 through a stencil mask 320, wherein openings in stencil mask 320 correspond to a desired layout of heater traces 390. Atoms 340 may be, for example, copper, molybdenum, alloys thereof, and/or other materials that are typically utilized for heater traces. Fixturing 330 holds stencil mask 320 in registration with chuck 300 so that thin film heater traces 390 form in desired locations on chuck 300. Atoms 340 that encounter openings in stencil mask 320 simply pass through stencil mask 320 and adhere to chuck 300, building up heater traces 390. Atoms 340 that encounter stencil mask 320 in areas that are not openings adhere to stencil mask 320. Sputtering of atoms 340 ceases when heater traces 390 reach their desired thickness. Thereafter, chuck 300 disengages from fixturing 330 such that stencil mask 320 and the sputtered atoms that have adhered thereto are removed.

2. Exemplary Photolithography Techniques

2A. Blanket Layer Deposition with Photolithography and Etch

FIG. 5 shows thin film heater traces 390 being formed by etching of a metal layer 350 that is first sputtered onto chuck 300 as a blanket layer, and is subsequently patterned using photolithography. A photoresist layer is applied and developed to yield a photoresist pattern 360 corresponding to a desired layout of heater traces 390. Exposure and development steps of photoresist pattern 360 are not shown. Either positive or negative photoresist and mask polarity may be utilized to generate pattern 360. For example, to use positive photoresist patterning, chuck 300 with a blanket layer 350 is first coated with positive photoresist, then exposed using a mask that blocks light exposure of areas intended as the heater traces. In positive photoresist, light breaks down the photoresist, allowing a development step to remove the photoresist that was exposed, leaving pattern 360 as illustrated in FIG. 5. Alternatively, to use negative photoresist patterning, chuck 300 with blanket layer 350 is coated with photoresist, then exposed using a mask that allows light exposure of areas intended as the heater traces. Light causes crosslinking of negative photoresist molecules, allowing the exposed areas to remain after a development step removes photoresist that was not exposed, leaving pattern 360 as illustrated in FIG. 5.

Once pattern 360 is generated, metal layer 350 that is exposed through openings in pattern 360 are etched by an etchant 370; FIG. 5 illustrates layer 350 in a partially etched state. Etchant 370 may be any etchant that etches layer 350 suitably and is compatible with material(s) of chuck 300 (e.g., etchant 370 may be chosen to etch layer 350 preferentially with respect to material(s) of chuck 300, but some etching of chuck 300 may be acceptable).

Completion of etching and removal of photoresist pattern 360 results in definition of one or more individual heater traces 390 in the configuration shown in FIG. 7.

2B. Photolithography Defining Regions for Selective Deposition, with Liftoff

FIG. 6 shows thin film heater traces 390 being formed by sputtering of atoms 340 onto chuck 300 that is patterned in an inverse photoresist image 380 of heater traces 390. Inverse image 380 is formed using photolithography, with either positive or negative photoresist and mask polarity, as described above. After inverse image 380 is formed, metal atoms 340 are sputtered in the direction of chuck 300. Atoms that encounter inverse photoresist image 380 adhere thereto, while atoms that pass through openings in image 380 adhere instead to chuck 300, forming heater traces 390. Sputtering of atoms 340 ceases when heater traces 390 reach their desired thickness. Thereafter, inverse photoresist image 380 and the sputtered atoms that have adhered thereto are removed. The techniques illustrated in FIGS. 4 and 6 can be considered similar in that each involves positioning a pattern in proximity to a chuck and sputtering atoms through the pattern to form the thin film heater traces.

Both the stencil mask technique illustrated in FIG. 4 and the photolithography techniques illustrated in FIGS. 5 and 6 are controllable to provide lateral dimension reproducibility on the order of a micron or less, while thick film techniques are typically controllable to provide lateral dimension reproducibility only on the order of tens of microns. Control of lateral dimensions is one principal source of improved dimensional control underlying improved control of resistance in thin film heater traces fabricated by sputtering. A second source of improved dimensional control is thickness control. Heater traces manufactured using thick film technology can have point to point variations (e.g., from point to point within traces of a given wafer chuck) on the order of tens of microns. Such variations translate directly to existence of hot spots (w)ere traces are thin) or cold spots (w)ere traces are thick) on the wafer chuck. Thin film heater traces manufactured using sputtering are expected to have point to point variations with a given wafer chuck that are only on the order of tenths or hundredths of a micron, with corresponding reduction in the tendency of the wafer chuck to have hot or cold spots. Also, typical current practice is to test resistance of heater traces as fabricated on a wafer chuck before integrating the wafer chuck into apiece of process equipment; it is believed that improved resistance variation control in the heater element as discussed above will enable removal of the testing step from the process equipment manufacturing flow, for additional cost savings. Net resistance variation among heater traces made utilizing thick film technology is rarely less than five percent, while net resistance variation among thin film heater traces made utilizing sputtering is expected to be less than two percent.

Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. Additionally, a number of well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present invention. Accordingly, the above description should not be taken as limiting the scope of the invention.

Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included.

As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context dearly dictates otherwise. Thus, for example, reference to “a process” includes a plurality of such processes and reference to “the wafer chuck” includes reference to one or more water chucks and equivalents thereof known to those skilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and “includes” when used in this specification and in the following claims are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, acts, or groups. 

What is claimed is:
 1. A method of forming thin film heater traces on a wafer chuck, comprising: positioning a pattern in proximity to the wafer chuck, the pattern forming openings corresponding to a desired layout of the thin film heater traces, and sputtering a material toward the pattern and the wafer chuck such that a portion of the material passes through the openings and adheres to the wafer chuck to form the thin film heater traces.
 2. The method of claim 1, the material comprising one or more of copper, molybdenum, and alloys thereof.
 3. The method of claim 1, wherein the desired layout includes landing pads configured for electrical connections to the thin film heater traces.
 4. The method of claim 3, further comprising depositing a dielectric layer over the thin film heater traces.
 5. The method of claim 4, further comprising opening vias through the dielectric layer to provide access for the electrical connections to the landing pads.
 6. The method of claim 1, the wafer chuck comprising ceramic.
 7. The method of claim 6, the ceramic forming vacuum channels configured to secure a wafer against the wafer chuck in proximity to the thin film heater traces.
 8. The method of claim 1, the wafer chuck comprising a conductor with an unbroken dielectric layer thereon, and wherein the thin film heater traces form on an opposite side of the unbroken dielectric layer from the conductor.
 9. The method of claim 8, the unbroken dielectric layer comprising a first dielectric layer, and further comprising depositing a second dielectric layer over the thin film heater traces.
 10. The method of claim 9, wherein the desired layout includes landing pads configured for electrical connections to the thin film heater traces, and further comprising opening vias through the second dielectric layer to provide access for the electrical connections to the landing pads.
 11. The method of claim 1, wherein: the pattern comprises a stencil mask; positioning comprises engaging the stencil mask in proximity to the wafer chuck using a fixture; and further comprising disengaging the stencil mask.
 12. The method of claim 1, wherein: the pattern comprises an inverse photoresist image formed by photolithography; positioning comprises forming the inverse photoresist image on the wafer chuck; and further comprising removing the inverse photoresist image.
 13. A method of forming thin film heater traces on a wafer chuck, comprising: sputtering a material onto the wafer chuck to form a blanket layer of the material; patterning a photoresist layer utilizing photolithography, the photoresist layer covering the blanket layer in an intended layout of the thin film heater traces, while exposing the blanket layer in areas that are not part of the intended layout; removing the areas that are not part of the intended layout by etching; and removing the photoresist layer.
 14. A heated wafer chuck for semiconductor processing, comprising: a wafer chuck having a dielectric surface; and one or more sputtered thin film heater traces, the one or more sputtered thin film heater traces comprising copper, molybdenum or alloys thereof, a layout of the thin film heater traces comprising landing pads for electrical connections; a dielectric layer overlying the one or more sputtered thin film heater traces, the dielectric layer forming vias over the landing pads for the electrical connections to make contact to the landing pads. 